Ceiling fan and method of installing a ceiling fan

ABSTRACT

A ceiling fan hanging system ( 10 ) in disclosed which includes a motor ( 12 ), a downrod coupler ( 13 ), a hollow downrod ( 15 ), and a canopy assembly ( 16 ). The downrod includes an elongated shaft ( 22 ) defined by a cylindrical sidewall ( 23 ) having window or access port ( 24 ) therein. An access panel ( 27 ) is removably mounted to the downrod shaft. The fan electrical wires or leads ( 34 ) extend from the motor upwardly through the downrod coupler and into the bottom end of the downrod. The electrical wire leads are spliced to the bottom end of a length of extension electrical wires ( 36 ) at the location of the window. The extension electrical wires extend upwardly through the interior of the downrod ( 15 ) and are coupled to the structure or building electrical wires at the canopy assembly.

TECHNICAL FIELD

This invention relates to ceiling fans and specifically to a ceiling fan downrod for quickly connecting ceiling fan motor electrical wiring and the method of accomplishing such.

BACKGROUND OF THE INVENTION

Traditionally, ceiling fans have been installed by a laborious, time consuming and often cumbersome practice. The conventional ceiling fan includes a ceiling plate which is secured to an electric outlet box by passing the lead wires of the outlet box through a central circular opening in the ceiling plate. Mounting screws are passed through two elongated openings in the ceiling plate to threadably engage with two threaded holes diagonally separated from each other on the periphery of the outlet box. Alternatively, wood screws are passed through the ceiling plate and the outlet box and into a wood stud which supports the outlet box. In either event, the screws are tightened until the ceiling plate is securely mounted on the outlet box. The typical ceiling plate includes a hanging hook.

When a typical ceiling fan assembly is mounted to the ceiling plate, the motor, fan blades and an optional light assembly are secured to a canopy by a hollow downrod or hanger rod. The downrod passes through a central opening in the canopy with a ball mount located at an end of the downrod engaged by a periphery of the opening of the canopy.

The structure's electrical wires extending through the ceiling to the ceiling plate are then connected to the ceiling fan's electrical lead wires extending from the fan motor upwardly through the downrod to a position adjacent the

Typically, a ceiling fan manufacturer provides the lead wires with a length which will allow it to be coupled with the structure's electrical wiring according to length of the ceiling fan's downrod. This length is typically enough to mount the ceiling fan to a relatively tall ceiling. However, if the ceiling fan is mounted to a relatively short ceiling, the ceiling fan's lead wires must be cut by the installer to the appropriate length. A problem arising in the opposite situation wherein a ceiling fan having lead wires for a short ceiling is installed on a taller ceiling requiring the connection of additional wiring to reach the structure's electrical wiring in the area of the ceiling plate. Governmental regulations prohibit the connection of electrical wiring within an enclosed raceway such as a ceiling tan downrod.

Accordingly, it is seen that a need has long existed for a ceiling fan that could be more easily and quickly mounted to ceilings of different heights. It thus is to the provision of such that the present invention is primarily directed.

SUMMARY OF THE PRESENT INVENTION

In a preferred form of the invention, a ceiling fan adapted to be coupled to a structure having electric wiring, the ceiling fan comprises an electric motor having electrical wiring leads, a canopy assembly adapted to be mounted to a ceiling of a structure, an elongated, hollow downrod having a bottom end coupled to the electric motor and a top end coupled to the canopy assembly, the hollow downrod having an access window extending therethrough, and an access panel moveable between a first position covering window and a second position exposing window.

In another preferred form of the invention, a method of installing a ceiling fan comprises the steps of (A) providing a ceiling fan having an electric motor having electrical wiring leads, a canopy assembly adapted to be mounted to a ceiling of a structure, an elongated, hollow downrod extending between the electric motor and the canopy assembly and having an access window extending therethrough, and an access panel coupleable to the downrod in a position covering the window, (B) moveable the access panel from a position covering the window to a position uncovering the window, (C) positioning the downrod to a position wherein a first end is located closely adjacent the downrod window, (D) pulling the electric motor electrical wiring leads and the first end of the length of extension electrical wires through the window to a position external of the downrod, (E) coupling the electric motor electrical wiring leads to the first end of the length of extension electrical wired, (F) moving the coupled electric motor electrical wiring leads and first end of the length of extension electrical wires back through the window and into the interior of the downrod, (G) moving the access panel back to a position covering the window, and (H) securing the access panel to the downrod in its window covering position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the ceiling fan in a preferred form of the invention.

FIG. 2 is a side view of the ceiling fan in another preferred form of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference next to the drawings, there is shown a ceiling fan 10 in a preferred form of the invention. The ceiling fan 10 includes a fan motor housing 11, a motor 12 positioned within the motor housing 11, a downrod coupler 13 mounted to the top end of the motor 12, and a hollow downrod 15 extending upwardly from a downrod coupler 13 to the ceiling fan canopy assembly 16 which is coupled to the ceiling of a structure. The ceiling fan also includes the conventionally known components, such as a plurality of fan blades 14, an unshown switch housing, and an unshown optional light kit.

The canopy 19 coupled to the mounting plate 17 and having a central opening 20 which is preferably trilobular in shape to received a trilobular ball 21 coupled to the end of the downrod 15. Alternatively, the canopy assembly may include a conventional ball receiving bracket positioned within the canopy. The canopy assembly 16 is generally of conventional

The downrod 15 includes an elongated shaft 22 defined by a cylindrical sidewall 23 having window or access port 24 therein. The window 24 is preferably located directly or closely adjacent the downrod coupler 13, however, the invention is not limited to such a positioning of the window. Two screw mounting holes 26 extend into the downrod sidewall adjacent opposite ends of the window 24. The downrod 15 also includes a curved access panel or door 27 having two screw mounting holes 28 therethrough which are alignable with the downrod screw mounting holes 26. Two mounting screws 30 pass through the access panel screw mounting holes 28 and are threaded into the downrod screw mounting holes 26 to allow the access panel 27 to be removably mounted to the downrod shaft. A rubber gasket 31 conforming to the configuration of the access panel 27 or window may be positioned between the access panel 27 and the downrod shaft 22 to prevent moisture from entering the interior of the downrod shaft 22 through the window 24. The gasket 31 includes screw mounting holes 32 which are also alignable with the downrod screw mounting holes 26.

The fan electrical wires or leads 34 extend from the motor 12, and optional light kit, upwardly through the downrod coupler 13 and into the bottom end of the downrod 15. The fan electrical wire leads 34 terminate at a position electrically coupled to the bottom end of a length of extension electrical wires 36 at the location of the window 24. The extension electrical wires 36 extend upwardly through the interior of the downrod 15 and through the ball 21. The top end of the extension electrical wires 36 are coupled or spliced to the structure or building electrical wires at the canopy assembly 16.

In use, an installer may calculate the length of extension electrical wires 36 necessary to extend from the downrod window 24 to the canopy assembly 16 and cut a length of extension electrical wires 36 accordingly. The cut may be made either prior to or subsequent to the insertion of the extension electrical wires into the downrod. The access panel 27 is removed from the downrod shaft 22 by removing the mounting screws 30 and exposing the underlying window 24. The bottom end of the extension electrical wires 36 may be passed through the hollow downrod 15 to the window 24, wherein the ends of the motor electrical wire leads 34 and extension electrical wires 36 are pulled through the window and spliced or coupled together. The opposite or top end of the extension electrical wires 36 are then spliced or coupled to the structure electrical wires at the location of the canopy assembly.

Once the wiring splices are complete the electrical wires or leads 34 and 36 are pushed back through the window 24 and into the interior of the downrod 15. The access panel 27 is then moved to its initial position secured to the downrod shaft 22 and covering the window 24 by passing mounting screws 30 through access panel and gasket mounting holes 28 and 32 and threading item into downrod mounting holes 26.

It should be understood that with the window 24 any length of electrical wires may be quickly and easily spliced to the motor and/or light kit electrical wires to provide a

With reference next to FIG. 2, there is shown a ceiling fan 10 in an alternative form of the invention. Here, the access panel is in the form of a cylindrical tube 40 rather than the curved plate design shown in FIG. 1. Here, the access panel is configured to fit over and slide upon the downrod shaft 22, i.e., the access panel is journalled upon the downrod shaft. To access the underlying window 24 the installer simply unthreads mounting screw 30 which passes through the cylindrical access panel mounting hole 28 and into the downrod shaft mounting hole 26 and lifts the access panel 27 along the downrod shaft 22 to expose the underlying window 24. Once the installation is complete, the access panel 27 is returned to its position overlying the window 24 and the mounting screw 30 is passed through the access panel mounting hole 28, through the optional gasket mounting hole 32, and re-threaded into the downrod shaft mounting hole 26. Again, an optional gasket may be incorporated to better seal the window from the elements.

It should be understood that as used herein the term “ceiling” of a structure is intended to include not only the conventional ceiling of a building or house, but also any other structure which can support a ceiling fan such as an exposed beam, post, or the like.

It thus is seen that a ceiling fan is now provided that overcomes problems associated with the prior art. It should be understood that many modifications may be made to the specific preferred embodiment described herein without departure from the spirit and scope of the invention as described by the following claims. 

1. A ceiling fan adapted to be coupled to a structure having electrical wiring, the ceiling fan comprising, an electric motor having electrical wiring leads, a canopy assembly adapted to be mounted to the ceiling of a structure, an elongated, hollow downrod having a sidewall, an open bottom end coupled to the electric motor, and an open top end coupled to the canopy assembly, the hollow downrod having an access window extending through the sidewall, and an access panel coupleable to the downrod and moveable between a first position covering the window and a second position exposing the window.
 2. The ceiling fan of claim 1 wherein the electrical wiring leads of the electric motor terminate at a location within the downrod closely adjacent the window.
 3. The ceiling fan of claim 2 further comprising extension electrical wires having a first end positioned within the downrod closely adjacent the window and electrically coupled to the electrical wiring leads of the electric motor and a second end extending from the top end of the downrod.
 4. The ceiling fan of claim 1 wherein the window is positioned closely adjacent the downrod bottom end and distal the downrod top end.
 5. The ceiling fan of claim 1 further comprising a gasket positioned between the access panel and the downrod.
 6. The ceiling fan of claim 1 wherein the access panel is a tubular access panel journalled upon the downrod.
 7. The ceiling fan of claim 1 wherein the access panel is a curved plate.
 8. A ceiling fan adapted to be coupled to a structure having electric wiring, the ceiling fan comprising: an electric motor having electrical wiring leads, a canopy assembly adapted to be mounted to the ceiling of a structure, an elongated, hollow downrod extending between the electric motor and the canopy assembly, the hollow downrod having a sidewall with an access window extending through the sidewall, the downrod housing the electric wiring leads within the interior of the downrod, and an access panel configured to cover the window when mounted to the downrod and be moved distally from the window to allow access to the electrical wiring leads of the electric motor positioned within the interior of the downrod through the window.
 9. The ceiling fan of claim 8 wherein the electrical wiring leads of the electric motor terminate at a location within the downrod closely adjacent the window.
 10. The ceiling fan of claim 9 further comprising extension electrical wires having a first end positioned within the downrod closely adjacent the window and electrically coupled to the electrical wiring leads of the electric motor and a second end extending from the top end of the downrod.
 11. The ceiling fan of claim 8 wherein the window is positioned closely adjacent the downrod bottom end and distal the downrod top end.
 12. The ceiling fan of claim 8 further comprising a gasket positioned between the access panel and the downrod.
 13. The ceiling fan of claim 8 wherein the access panel is a tubular access panel journalled upon the downrod.
 14. The ceiling fan of claim 8 wherein the access panel is a curved plate.
 15. A method of installing a ceiling fan: having an electric motor having electrical wiring leads, a canopy assembly adapted to be mounted to a ceiling of a structure, an elongated, hollow downrod extending between the electric motor and the canopy assembly and having an access window extending therethrough, and an access panel coupleable to the downrod in a position covering the window, the method comprising: moving the access panel from a position covering the window to a position uncovering the window, positioning a length of extension electrical wires through the interior of the downrod to a position wherein a first end is located closely adjacent the downrod window, pulling the electric motor electrical wiring leads and the first end of the length of extension electrical wires through the window to a position external of the downrod, coupling the electric motor electrical wiring leads to the first end of the length of extension electrical wires, moving the coupled electric motor electrical wiring leads and first end of the length of extension electrical wires back through the window and into the interior of the downrod, moving the access panel back to a position covering the window, and securing the access panel to the downrod in its window covering position.
 16. The method of claim 15 further comprising the step (I) coupling a second end of the length of extension electrical wires to the electrical wires of a structure.
 17. The method of claim 15 wherein the length of extension electrical wires is cut to a select length located generally in the area of the canopy assembly.
 18. A ceiling fan adapted to be coupled to a structure having electric wiring, the ceiling fan comprising: an electric motor having electrical wiring leads, an elongated, hollow downrod having a sidewall, an open bottom end coupled to the electric motor, and an open top end, the hollow downrod having an access opening extending through the sidewall, and an access panel coupled to the downrod and moveable between a first position, closing the window, and a second position, opening the window.
 19. The ceiling fan of claim 18 wherein the access panel comprises a plate removably mounted to the downrod, wherein when the plate is mounted to the downrod, the access panel is in the first position, and when the plate is removed from the downrod, the access panel is in the second position.
 20. The ceiling fan of claim 19 wherein the plate is curved.
 21. The ceiling fan of claim 18 wherein the access panel comprises a tube slidably mounted to the downrod, wherein the tube slides relative to the downrod between the first and second positions.
 22. The ceiling fan of claim 18 comprising a gasket between the access panel and the downrod when the access panel is in the first position.
 23. The ceiling fan of claim 18 wherein the wiring leads are of a length to extend into the downrod at least up to the window when the downrod is mounted to the electric motor.
 24. The ceiling fan of claim 18 further comprising a ceiling bracket configured to couple with the top end of the downrod.
 25. The ceiling fan of claim 24 further comprising a trilobular ball coupling the top end of the downrod to the ceiling bracket.
 26. The ceiling fan of claim 25 further comprising a canopy provided about the trilobular ball.
 27. The ceiling fan of claim 18 wherein the access panel is slidably mounted to the downrod.
 28. The ceiling fan of claim 18 wherein the access panel is mechanically mounted to the downrod.
 29. A ceiling fan kit comprising: an electric motor having electrical wiring leads, fan blades, an elongated, hollow downrod having a sidewall, an open bottom end, an open top end, and an access opening extending through the sidewall, an access panel coupled to the downrod and moveable between a first position, closing the window, and a second position, opening the window, and a ceiling bracket.
 30. The ceiling fan kit of claim 29 further comprising extension electrical wires.
 31. The ceiling fan kit of claim 29 further comprising a canopy.
 32. The ceiling fan kit of claim 29 further comprising a trilobular ball.
 33. The ceiling fan kit of claim 29 further comprising a gasket.
 34. A ceiling fan downrod kit comprising: an elongated, hollow downrod having a sidewall, an open bottom end, an open top end, and an access opening extending through the sidewall, and an access panel coupled to the downrod and moveable between a first position, closing the window, and a second position, opening the window.
 35. The ceiling fan downrod kit of claim 34 further comprising extension electrical wires.
 36. The ceiling fan downrod kit of claim 34 further comprising a gasket.
 37. The ceiling fan downrod kit of claim 34 wherein the access panel is a tube.
 38. The ceiling fan downrod kit of claim 34 wherein the access panel is a plate. 